Energy storage system for a hybrid vehicle

ABSTRACT

An energy storage system, for a hybrid vehicle including an internal combustion engine having an output shaft and a transmission operably coupled to the output shaft, includes a reservoir containing working fluid, a reversible pump/motor in fluid communication with the reservoir, a first clutch selectively drivably coupling the output shaft of the engine and the reversible pump/motor, a second clutch selectively drivably coupling an output shaft of the transmission and the reversible pump/motor, and an accumulator containing working fluid and gas. The accumulator is in fluid communication with the reversible pump/motor to deliver pressurized working fluid to the reversible pump/motor when operating as a motor to drive one of the respective output shafts of the engine and the transmission, and to receive pressurized working fluid discharged by the reversible pump/motor when operating as a pump driven by the one of the respective output shafts of the engine and the transmission.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of co-pending U.S. patent application Ser. No. 12/361,236 filed Jan. 28, 2009, the entire content of which is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to hybrid drive systems for vehicles and more particularly to hybrid hydraulic drive systems for vehicles.

BACKGROUND OF THE INVENTION

A typical vehicle hybrid hydraulic drive system uses a reversible pump/motor to absorb power from and add power to or assist a conventional vehicle drive system. The system absorbs power by pumping hydraulic fluid from a low pressure reservoir into a hydraulic energy storage system. This hydraulic energy storage system typically includes one or more nitrogen-charged hydraulic accumulators. Hybrid hydraulic drive systems typically add power to conventional vehicle drive systems by utilizing the hydraulic energy stored in the hydraulic accumulators to drive the reversible pump/motor as a motor.

SUMMARY OF THE INVENTION

The present invention provides, in one aspect, an energy storage system for a hybrid vehicle including an internal combustion engine having an output shaft and a transmission operably coupled to the output shaft. The energy storage system includes a reservoir containing working fluid, a reversible pump/motor in fluid communication with the reservoir, a first clutch selectively drivably coupling the output shaft of the engine and the reversible pump/motor, a second clutch selectively drivably coupling an output shaft of the transmission and the reversible pump/motor, and an accumulator containing working fluid and gas. The accumulator is in fluid communication with the reversible pump/motor to deliver pressurized working fluid to the reversible pump/motor when operating as a motor to drive one of the respective output shafts of the engine and the transmission, and to receive pressurized working fluid discharged by the reversible pump/motor when operating as a pump driven by the one of the respective output shafts of the engine and the transmission.

The present invention provides, in another aspect, a method of operating a hybrid vehicle including an internal combustion engine having an output shaft and a transmission operably coupled to the output shaft. The method includes providing an accumulator containing working fluid and gas, providing a reversible pump/motor, selectively drivably coupling the output shaft of the engine and the reversible pump/motor to operate the reversible pump/motor at a first speed, selectively drivably coupling an output shaft of the transmission and the reversible pump/motor to operate the reversible pump/motor at a second speed different than the first speed, and discharging pressurized working fluid from the accumulator to the reversible pump/motor when operating as a motor, and receiving pressurized working fluid discharged by the reversible pump/motor when operating as a pump.

Other features and aspects of the invention will become apparent by consideration of the following detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic of a first construction of an energy storage system for a hybrid vehicle of the present invention.

FIG. 2 is a schematic of a second construction of an energy storage system for a hybrid vehicle of the present invention.

FIG. 3 is a schematic of a third construction of an energy storage system for a hybrid vehicle of the present invention.

FIG. 4 is a schematic of a fourth construction of an energy storage system for a hybrid vehicle of the present invention.

FIG. 5 is a graph of flow rate versus engine speed of the data included in Table 1.

FIG. 6 is a graph of flow rate versus engine speed of the data included in Table 2.

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.

DETAILED DESCRIPTION

FIG. 1 illustrates a schematic of a first construction of an energy storage system 10 for a hybrid vehicle 14 including an internal combustion engine 18 and a multi-speed transmission 22 (e.g., a planetary automatic transmission 22 utilizing a torque converter 26) coupled to the engine 18. Specifically, as shown in FIG. 1, the torque converter 26 includes a pump or turbine 30 non-rotatably coupled to an output shaft 34 (e.g., a crankshaft) of the engine 18, an impeller 38 non-rotatably coupled to an input shaft 42 of the transmission 22, and a stator 46. Alternatively, the transmission 22 may be configured as a manual transmission. The transmission 22 further includes an output shaft 50 that transfers power from the transmission 22 to a rear differential 54 in the vehicle's driveline. A pair of rear wheels 58 is driven by the rear differential 54 in a conventional manner. Although not shown, a front differential in combination with a secondary gearbox (e.g., a four-wheel drive transfer case) may transfer power from the engine 18 to a pair of front wheels 62 of the vehicle 14.

The energy storage system 10 illustrated in FIG. 1 is configured as a parallel hydraulic regenerative drive system including a reservoir 66, an accumulator 70 in selective fluid communication with the reservoir 66, and dual reversible pump/motors 74, 78 operably coupled to the accumulator 70. Each of the reversible pump/motors 74, 78 is configured as a variable displacement, axial-piston, swashplate-design pump/motor, such as a Bosch Rexroth Model No. A4VSO variable displacement, axial piston reversible pump/motor. Each of the reversible pump/motors 74, 78 includes a different maximum displacement and a maximum permissible operating speed. In the illustrated construction of the system, the first reversible pump/motor 74 is sized having a maximum displacement of 125 cubic centimeters per revolution (“cc/rev”) of the input shaft of the pump/motor 74, and the second reversible pump/motor 78 is sized having a maximum displacement of 355 cc/rev of the input shaft of the pump/motor 78. Alternatively, the first and second reversible pump/motors 74, 78 may be sized having different maximum displacements depending upon the particular configuration or size of the vehicle 14. Further, one or both of the reversible pump/motors 74, 78 may be configured having a constant displacement rather than a variable displacement.

With continued reference to FIG. 1, the accumulator 70 includes a first chamber 82 containing a gas (e.g. nitrogen, etc.), a second chamber 86 containing a working fluid (e.g. hydraulic fluid, etc.), and a movable piston 90 separating the chambers 82, 86 (schematically illustrated as a line between the chamber 82 and the chamber 86). Alternatively, the accumulator 70 may be configured with a bladder or a diaphragm rather than the piston 90. The system 10 also includes an isolation valve 94 in fluid communication with the working fluid chamber 86 in the accumulator 70 by a fluid passageway 98. The isolation valve 94 may be configured as a poppet valve, ball valve, spool valve, gate valve, cartridge valve, needle valve, block valve, etc. Further, the isolation valve 94 is solenoid-actuated to open and spring-biased to close.

With continued reference to FIG. 1, the reservoir 66 contains working fluid and includes a breather 102. The breather 102 provides venting of the space above the working fluid in the reservoir 66 as the level of working fluid fluctuates during operation of the system 10. The breather 102 is exposed to the atmosphere, such that gas in the reservoir 66 may be vented to the atmosphere, and replacement air may be allowed to enter the reservoir 66 when the level of working fluid in the reservoir 66 decreases. Alternatively, the breather 102 may be fluidly connected to an auxiliary tank or vessel (not shown) to contain gas vented from the reservoir 66, or the reservoir 66 may be pressurized from an external source. The reservoir 66 is in fluid communication with the reversible pump/motors 74, 78 by separate fluid passageways 106, 114. Another fluid passageway 110 selectively fluidly communicates the accumulator 70 and the reservoir 66, and another isolation valve 118 is positioned in the fluid passageway 110. In addition, a pressure relief valve 122 is positioned in a fluid passageway 126 providing a bypass from the fluid passageway 98 to the fluid passageway 110. A heat exchanger 130 and a working fluid filter 134 are in fluid communication with the reversible pump/motors 74, 78 and the reservoir 66 and are situated in the fluid passageway 114.

With continued reference to FIG. 1, the first reversible pump/motor 74 is drivably coupled to the output shaft 34 of the engine 18 at a location forward of the transmission 22 (i.e., relative to the front and rear of the vehicle 14). Specifically, the reversible pump/motor 74 is drivably coupled to an accessory drive system 138 located near the front of the engine 18. Alternatively, in a transverse mounting arrangement of the engine 18, the reversible pump/motor 74 may be drivably coupled to an accessory drive system located near the side of the engine 18 relative to its placement in the vehicle 14. The accessory drive system 138 may include a plurality of engine accessories (e.g., an alternator, an air-conditioning compressor, an air pump, a coolant pump etc.), a plurality of pulleys non-rotatably coupled to each of the respective accessories, and one or more belts arranged to at least partially wrap around each of the pulleys to power the respective accessories. The accessory drive system 138 also includes an offset gearbox 142 operable to transfer torque between the output shaft 34 of the engine 18 and the first reversible pump/motor 74. Although the illustrated offset gearbox 142 is configured having a 1:1 input/output ratio, the gearbox 142 may be configured having a lower or higher input/output ratio.

Also, in the illustrated construction of the system 10, a clutch 146 is positioned between the first reversible pump/motor 74 and the output shaft 34 of the engine 18 to allow the first reversible pump/motor 74 to be selectively drivably coupled to the engine output shaft 34. As shown in FIG. 1, an engine control unit 150 (i.e., “ECU”) of the vehicle 14 is operable to selectively actuate the clutch 146 between a disengaged configuration, in which no torque transfer occurs between the engine output shaft 34 and the first reversible pump/motor 74, and an engaged configuration, in which torque transfer occurs between the engine output shaft 34 and the first reversible pump/motor 74. The clutch 146 may be configured as an electric clutch or an electromagnetic clutch operable to interface directly with the ECU 150, or the clutch 146 may be pneumatically or hydraulically actuated by the ECU 150 through an intermediate controller (not shown). Also, the ECU 150 may control the degree of engagement of the clutch 146 (e.g., by controlling the amount of voltage or fluid pressure delivered to the clutch 146), such that a variable amount of torque may be transferred between the engine output shaft 34 and the first reversible pump/motor 74 due to a controlled amount of slippage in the clutch 146. The connection between the ECU 150 and the clutch 146 (indicated by letter “A”) may be wired or wireless (for an electric or electromagnetic clutch configuration), or, the connection between the ECU 150 and the intermediate controller for the pneumatically or hydraulically-actuated clutch 146 may be wired or wireless.

With continued reference to FIG. 1, the second reversible pump/motor 78 is drivably coupled to the output shaft 50 of the transmission 22 at a location rearward of the transmission 22 (i.e., relative to the front and rear of the vehicle 14). Like the first reversible pump/motor 74 described above, the second reversible pump/motor 78 is drivably coupled to the transmission output shaft 50 via an offset gearbox 154 operable to transfer torque between the transmission output shaft 50 and the second reversible pump/motor 78. Although the illustrated offset gearbox 154 is configured having a 1:1 input/output ratio, the gearbox 154 may be configured having a lower or higher input/output ratio. Another output shaft 158 interconnects the offset gearbox 154 and the rear differential 54. Alternatively, the output shaft 158 may be omitted, and the gearbox 154 may be directly coupled to the rear differential 54. As a further alternative, the output shaft 50 may be omitted and the gearbox 154 may be directly coupled to the transmission 22.

Also, in the illustrated construction of the system 10, a clutch 162 is positioned between the second reversible pump/motor 78 and the output shaft 50 of the transmission 22 to allow the second reversible pump/motor 78 to be selectively drivably coupled to the transmission output shaft 50. In a manner similar to that described above with respect to the first reversible pump/motor 74, the ECU 150 is operable to selectively actuate the clutch 162 between a disengaged configuration, in which no torque transfer occurs between the transmission output shaft 50 and the second reversible pump/motor 78, and an engaged configuration, in which torque transfer occurs between the transmission output shaft 50 and the second reversible pump/motor 78. The clutch 162 may be configured as an electric clutch or an electromagnetic clutch operable to interface directly with the ECU 150, or the clutch 162 may be pneumatically or hydraulically actuated by the ECU 150 through an intermediate controller (not shown). The ECU 150 may control the degree of engagement of the clutch 162, such that a variable amount of torque may be transferred between the transmission output shaft 50 and the second reversible pump/motor 78 due to a controlled amount of slippage in the clutch 162. The connection between the ECU 150 and the clutch 162 (indicated by letter “B”) may be wired or wireless (for an electric or electromagnetic clutch configuration), or, the connection between the ECU 150 and the intermediate controller for the pneumatically or hydraulically-actuated clutch 162 may be wired or wireless.

With continued reference to FIG. 1, the first reversible pump/motor 74 is in fluid communication with the reservoir 66 to receive low-pressure working fluid via the fluid passageway 106 and a fluid passageway branch 106′. Likewise, the second reversible pump/motor 78 is in fluid communication with the reservoir 66 to receive low-pressure working fluid via the fluid passageway 106 and a fluid passageway branch 106″. As such, the first and second reversible pump/motors 74, 78 draw low-pressure working fluid from the reservoir 66 in parallel with each other. Alternatively, separate, dedicated fluid passageways may be utilized for each of the reversible pump/motors 74, 78 to draw low-pressure working fluid from the reservoir 66.

Further, the first reversible pump/motor 74 is in fluid communication with the accumulator 70 via the fluid passageway 98 and a fluid passageway branch 98′ to deliver pressurized working fluid to the accumulator 70 when operating as a pump, and to receive pressurized working fluid from the accumulator 70 when operating as a motor. Likewise, the second reversible pump/motor 78 is in fluid communication with the accumulator 70 via the fluid passageway 98 and a fluid passageway branch 98″ to deliver pressurized working fluid to the accumulator 70 when operating as a pump, and to receive pressurized working fluid from the accumulator 70 when operating as a motor. As such, the first and second reversible pump/motors 74, 78 may discharge pressurized working fluid to the accumulator 70 in parallel with each other and receive pressurized working fluid from the accumulator 70 in parallel with each other. Alternatively, separate, dedicated fluid passageways may be utilized for each of the reversible pump/motors 74, 78 to discharge pressurized working fluid to the accumulator 70 or receive pressurized working fluid from the accumulator 70.

With continued reference to FIG. 1, the first reversible pump/motor 74 is also in fluid communication with the reservoir 66 to return low-pressure working fluid to the reservoir 66 via the fluid passageway 114 and a fluid passageway branch 114′. Likewise, the second reversible pump/motor 78 is in fluid communication with the reservoir 66 to return low-pressure working fluid to the reservoir 66 via the fluid passageway 114 and a fluid passageway branch 114″. As such, the first and second reversible pump/motors 74, 78 may return low-pressure working fluid to the reservoir 66 in parallel with each other. Alternatively, separate, dedicated fluid passageways may be utilized for each of the reversible pump/motors 74, 78 to return low-pressure working fluid to the reservoir 66.

The energy storage system 10 also includes isolation valves 166, 170 positioned in the respective fluid passageway branches 98′, 98″ to selectively block the flow of working fluid through the fluid passageway branches 98′, 98″. The isolation valves 166, 170 may be configured as poppet valves, ball valves, spool valves, gate valves, cartridge valves, needle valves, block valves, etc. Further, each of the isolation valves 166, 170 is solenoid-actuated to open and spring-biased to close. The ECU 150 controls the actuation of the valves 166, 170 to open the valves 166, 170 and to allow the valves 166, 170 to close. The connection between the ECU 150 and each of the valves 166, 170 (indicated by letters “C” and “D,” respectively) may be wired or wireless. In addition, the connection between the ECU 150 and the valve 94 (indicated by letter “E”) may be wired or wireless. In addition, each of the isolation valves 166, 170 is selectively fluidly connected to the passageway 106 via a passageway 172 to provide a leak path to the reservoir 66 should one or both of the isolation valves 166, 170 fail.

By positioning the first reversible pump/motor 74 forward or upstream of the transmission 22 and the second reversible pump/motor 78 rearward or downstream of the transmission 22, the energy storage system 10 is operable in several different modes. In a first mode, for example, when it is desired to decelerate or reduce the speed of the vehicle 14, the second reversible pump/motor 78 is operable as a pump driven by the vehicle's axle or driveline (i.e., the rear wheels 58, rear differential 54, and the transmission output shafts 50, 158) to recover the kinetic energy of the vehicle 14. Upon sensing the braking or equivalent energy-absorption condition, the ECU 150 engages the clutch 162 and actuates the isolation valves 94, 170 to open the valves 94, 170. Then, the second reversible pump/motor 78 draws low-pressure working fluid from the reservoir 66 through the fluid passageway 106, through the fluid passageway branch 106″, and pressurizes the working fluid. The resultant pressurized working fluid is discharged from the reversible pump/motor 78, flows through the fluid passageway branch 98″ in the direction of arrow A before converging into the fluid passageway 98, through the fluid passageway 98, through the isolation valve 94, and into the working fluid chamber 86 of the accumulator 70. The isolation valve 118 in the fluid passageway 110 remains closed to prevent the pressurized working fluid from returning to the reservoir 66. As the pressurized working fluid flows into the accumulator 70, the piston 90 is displaced upwardly, thereby compressing the gas in the accumulator 70. The work performed by the piston 90 to compress the gas is stored for later use to power the axle or driveline of the vehicle 14. Alternatively, the stored energy in the accumulator 70 may be used to provide power to an auxiliary hydraulic system of the vehicle 14 (e.g., a tailgate lift or hoist, a winch, a hydraulic cylinder, etc.). As a further alternative, the pressurized working fluid provided by the second reversible pump/motor 78 may be immediately used, rather than being stored in the accumulator 70, to provide power to the vehicle's auxiliary hydraulic system.

Of course, this mode of operation of the system 10 is only available when the vehicle 14 is moving because an input torque to the second reversible pump/motor 78 is required to operate the pump/motor 78 as a pump. However, because the first reversible pump/motor 74 is positioned forward of the transmission 22, the first reversible pump/motor 74 may be provided with a torque input from the engine 18 when the vehicle 14 is either stationary or moving. As such, in another mode of operation of the system 10, the first reversible pump/motor 74 is operable as a pump to recover the rotational kinetic energy of the engine output shaft 34 when ignition to the engine 18 is turned off (e.g., when the vehicle is decelerating or stationary to reduce extended periods of engine idling). In yet another mode of operation of the system 10, the first reversible pump/motor 74 is operable as a pump using a torque input from the engine 18 to provide pressurized working fluid, either directly or via the accumulator 70, to the auxiliary hydraulic system of the vehicle 14 to power the auxiliary hydraulic system regardless of whether the vehicle 14 is stationary or moving. In a further mode of operation of the system 10, the first reversible pump/motor 74 is operable as a pump using a torque input from the engine 18 to provide pressurized working fluid to the accumulator 70 to pre-charge the accumulator 70 prior to movement of the vehicle 14.

To operate the first reversible pump/motor 74 as a pump under any of the above-described modes of operation of the system 10, the ECU 150 engages the clutch 146 and actuates the isolation valves 94, 166 to open the valves 94, 166. Then, the first reversible pump/motor 74 draws low-pressure working fluid from the reservoir 66 through the fluid passageway 106, through the fluid passageway branch 106′, and pressurizes the working fluid. The resultant pressurized working fluid is discharged from the reversible pump/motor 74, flows through the fluid passageway branch 98′ in the direction of arrow A before converging into the fluid passageway 98, through the fluid passageway 98, through the isolation valve 94, and into the working fluid chamber 86 of the accumulator 70. The isolation valve 118 in the fluid passageway 110 remains closed to prevent the pressurized working fluid from returning to the reservoir 66.

In a mode of operation of the system 10 in which both of the reversible pump/motors 74, 78 are operating as pumps using torque inputs from the engine output shaft 34 and the transmission output shaft 50, respectively, the ECU 150 may control the torque input delivered to each of the reversible pump/motors 74, 78 (e.g., by varying the engagement of the respective clutches 146, 162) to provide an optimized flow rate of the pressurized working fluid produced by the combination of the first and second reversible pump/motors 74, 78. Table 1 below illustrates the maximum flow rates that the first and second reversible pump/motors 74, 78 (i.e., the “engine-driven pump/motor” and the “driveline-driven pump/motor,” respectively) are capable of creating, with respect to the rotational speed of the engine 18 and the particular gear ratio of the transmission 22. The values used for the transmission gear ratios include: 6.34:1 first gear; 3.44:1 second gear; 1.71:1 third gear; 1:1 fourth gear; and 0.78:1 fifth gear.

TABLE 1 Engine- Driveline-driven Driveline-driven Driveline-driven Driveline-driven Driveline-driven driven pump/motor pump/motor pump/motor pump/motor pump/motor Engine pump/motor flow rate flow rate flow rate flow rate flow rate Speed flow rate (liters/min; 1st (liters/min; 2nd (liters/min; 3rd (liters/min; 4th (liters/min; 5th (rpm) (liters/min) gear) gear) gear) gear) gear) 0 0 No fluid output when vehicle is idling and stationary 100 13 200 25 300 38 400 50 500 63 600 75 700 88 39 72 145 249 319 800 100 45 83 166 284 364 900 113 50 93 187 320 410 1000 125 56 103 208 355 455 1100 138 62 114 228 391 501 1200 150 67 124 249 426 546 1300 163 73 134 270 462 592 1400 175 78 144 291 497 1500 188 84 155 311 533 1600 200 90 165 332 568 1700 213 95 175 353 604 1800 225 101 186 374 These values 1900 238 106 196 394 exceed the 2000 250 112 206 415 maximum 2100 263 118 217 436 permissible 2200 275 123 227 457 operating 2300 These values 129 237 477 speed of the 2400 exceed the 134 248 498 Rexroth A4VSO 2500 maximum 140 258 519 355 cc/rev 2600 permissible 146 268 540 pump/motor 2700 operating 151 279 561 2800 speed of 157 289 581 2900 the Rexroth 162 299 602 3000 A4VSO 168 310 3100 125 cc/rev 174 320 3200 pump/motor 179 330 3300 185 341 3400 190 351 3500 196 361 3600 202 372 3700 207 382 3800 213 392 3900 218 402 4000 224 413 4100 230 423 4200 235 433 4300 241 444 4400 246 454 4500 252 464 4600 258 475 4700 263 485 4800 269 495 4900 274 506 5000 280 516

As can be seen in Table 1, the maximum permissible operating speed of each of the first and second reversible pump/motors 74, 78 serves as a limitation on when each of the reversible pump/motors 74, 78 can operate as pumps within the operational range of the engine 18 (i.e., 0-5000 rpm) and the vehicle 14 (i.e., first through fifth gears). Table 1 is illustrated graphically in FIG. 5.

With reference to FIG. 5, should the system 10 require a flow rate of pressurized working fluid at any time when the engine 18 is operating below about 700 rpm (i.e., while the engine 18 is idling and the vehicle 14 is stationary), the first reversible pump/motor 74 must be used because no torque input is provided to the second reversible pump/motor 78 when the vehicle 14 is stationary. Likewise, should the system 10 require a flow rate of pressurized working fluid at any time when the engine 18 is operating above about 2200 rpm (i.e., the maximum operating speed of the pump/motor 74), the second reversible pump/motor 78 must be used. However, the second reversible pump/motor 78 is only operable during operation of the vehicle 14 in first, second, and third gears of the transmission 22 above an engine speed of about 2200 rpm. Further, as discussed above, the ECU 150 may control the torque input delivered to each of the reversible pump/motors 74, 78 to provide an optimized flow rate of the pressurized working fluid produced by the combination of the first and second reversible pump/motors 74, 78. For example, the auxiliary hydraulic system of the vehicle 14 might require a flow rate of pressurized working fluid of about 250 liters/min when the engine 18 is operating between about 1000-1500 rpm and the transmission 22 is in fourth gear. To accommodate this requirement, the ECU 150 may partially engage both of the clutches 146, 162 to deliver a torque input to each of the first and second reversible pump/motors 74, 78 to operate the respective pump/motors 74, 78 as pumps to provide a combined flow rate of about 200 liters/min. By incorporating this capability into the system 10, the functionality and efficiency of the system 10 is increased over the operating range of the engine 18 (i.e., 0-5000 rpm) and the vehicle 14 (i.e., first through fifth gears). It should be understood that the data provided in Table 1 and FIG. 5 is representative of reversible pump/motors having a displacement of 125 cc/rev and 355 rev/min, respectively, and a five-speed transmission having the gear ratios described above. Alternatively, different flow rate data than that shown in Table 1 and FIG. 5 would result from using reversible pump/motors having different displacements and/or a transmission having a different number of speeds and/or gear ratios.

When the vehicle 14 undergoes acceleration or another operation where propulsion assistance is needed, one or both of the reversible pump/motors 74, 78 function as a motor. The compressed gas acts on the piston 90 in the accumulator 70, thereby maintaining the working fluid at a high pressure. Upon sensing the acceleration condition (e.g., using input from a throttle position sensor), the ECU 150 engages the clutches 146, 162 and actuates the isolation valves 94, 166, 170 to open the valves 94, 166, 170 and permit the flow of pressurized working fluid in the direction of arrow B. High-pressure working fluid flows from the accumulator 70, through the fluid passageway 98, through the respective fluid passageway branches 98′, 98″, and into the respective reversible pump/motors 74, 78 to drive the reversible pump/motors 74, 78. The first reversible pump/motor 74 provides an additional torque input to the output shaft 34 of the engine 18, while the second reversible pump/motor 78 provides an additional torque input to the output shaft 50 of the transmission 22, thereby assisting the vehicle's acceleration or other energy-expending operation. The isolation valve 118 in the fluid passageway 110 would remain closed to prevent the pressurized working fluid from directly returning to the reservoir 66. Low-pressure working fluid then exits the reversible pump/motors 74, 78, flows through the respective fluid passageway branches 114′, 114″ in the direction of arrow C before converging into the fluid passageway 114, through the working fluid passageway 114, through the heat exchanger 130 and the filter 134 positioned in the fluid passageway 114, and is subsequently returned to the reservoir 66. Alternatively, only the second reversible pump/motor 78 may be employed to provide an additional torque input to the transmission output shaft 50 because of the inherent inefficiencies or losses associated with torque transfer through the torque converter 26. Also, the larger size or displacement of the second reversible pump/motor 78 would allow the pump/motor 78 when operating as a motor to provide a larger additional torque input to the vehicle's driveline with higher efficiency compared to the additional torque input available from the first reversible pump/motor 74.

In yet another mode of operation of the system 10, the first reversible pump/motor 74 may be operable as a motor to start the engine 18 using energy stored in the accumulator 70. This mode of operation may be employed to turn off the engine 18 when the vehicle 14 is stationary to reduce extended periods of engine idling. In another mode of operation of the system 10, the first reversible pump/motor 74 may be operable as a pump to circulate working fluid through the heat exchanger 130 and filter 134 to cool the working fluid and remove debris from the working fluid, respectively, when the vehicle 14 is stationary and/or prior to movement of the vehicle 14. Further, in yet another mode of operation of the system 10, the first reversible pump/motor 74 may be operable as a pump to circulate working fluid through the system 10 to pre-heat the working fluid prior to movement or operation of the vehicle 14. In these modes of operation in which the reversible pump/motor 74 is operating as a pump, the ECU 150 may open the valve 118 to allow the circulating working fluid to flow through the passageway 110 prior to merging with the fluid passageway 114 including the heat exchanger 130 and filter 134.

FIG. 2 illustrates a schematic of a second construction of an energy storage system 10 a for a hybrid vehicle 14 a, with like components having like reference numerals with the addition of letter “a.” Particularly, the energy storage system 10 a differs from the energy storage system 10 of FIG. 1 in that the first reversible pump/motor 74 a is positioned between the engine 18 a and the transmission 22 a, and the reversible pump/motor 74 a is drivably coupled to a power take-off (i.e., a “live” PTO interface with the transmission 22 a) of the engine 18 a, typically positioned near the front of the transmission 22 a. In other words, the power take-off may include a shaft in the transmission 22 a that is positioned forward of the torque converter 26 a and is directly connected to the engine output shaft 34 a and rotating at the same speed as the engine output shaft 34 a. Alternatively, the turbine 30 a of the torque converter 26 a may also function as the power take-off to which the first reversible pump/motor 74 a is drivably coupled. Depending upon the particular configuration of the vehicle incorporating the energy storage system 10 or 10 a, the energy storage system 10 a may be more desirable than the system 10 (e.g. the vehicle 14 a may not utilize a front accessory drive system such as the accessory drive system 138 shown in FIG. 1). The operation of the energy storage system 10 a is substantially similar to that described above for the energy storage system 10 of FIG. 1.

FIG. 3 illustrates a schematic of a third construction of an energy storage system 10 b for a hybrid vehicle 14 b, with like components having like reference numerals with the addition of letter “b.” The primary difference between the energy storage system 10 b illustrated in FIG. 3 and the energy storage system 10 illustrated in FIG. 1 is that the system 10 b includes only a single reversible pump/motor 174 operably coupled to the accumulator 70 b. The reversible pump/motor 174 is configured as a variable displacement, axial-piston, swashplate-design pump/motor, such as a Bosch Rexroth Model No. A4VSO variable displacement, axial piston reversible pump/motor. Similar to the system 10 of FIG. 1, the reversible pump/motor 174 is sized having a maximum displacement of 125 cc/rev of the input shaft of the pump/motor 174. Alternatively, the reversible pump/motor 174 may be sized having a different maximum displacement depending upon the particular configuration of the vehicle 14 a. Further, the reversible pump/motor 174 may be configured having a constant displacement rather than a variable displacement.

With continued reference to FIG. 3, the reversible pump/motor 174 is selectively drivably coupled to the output shaft 34 b of the engine 18 b at a location forward of the transmission 22 b (i.e., relative to the front and rear of the vehicle 14 b). Specifically, the reversible pump/motor 174 is selectively drivably coupled to an accessory drive system 138 b located near the front of the engine 18 b. Alternatively, in a transverse mounting arrangement of the engine 18 b, the reversible pump/motor 174 may be selectively drivably coupled to an accessory drive system located near the side of the engine 18 b relative to its placement in the vehicle 14 b. The accessory drive system 138 b also includes an offset gearbox 142 b operable to transfer torque between the engine output shaft 34 b and the reversible pump/motor 174. Although the illustrated offset gearbox 142 b is configured having a 1:1 input/output ratio, the gearbox 142 b may be configured having a lower or higher input/output ratio.

Also, in the illustrated construction of the system 10 b, a first clutch 178 is positioned between the reversible pump/motor 174 and the engine output shaft 34 b to allow the reversible pump/motor 174 to be selectively drivably coupled to the engine output shaft 34 b. As shown in FIG. 3, an ECU 150 b of the vehicle 14 b is operable to selectively actuate the clutch 178 between a disengaged configuration, in which no torque transfer occurs between the engine output shaft 34 b and the reversible pump/motor 174, and an engaged configuration, in which torque transfer occurs between the engine output shaft 34 b and the reversible pump/motor 174. The clutch 178 may be configured as an electric clutch or an electromagnetic clutch operable to interface directly with the ECU 150 b, or the clutch 178 may be pneumatically or hydraulically actuated by the ECU 150 b through an intermediate controller (not shown). Also, the ECU 150 b may control the degree of engagement of the clutch 178, such that a variable amount of torque may be transferred between the engine output shaft 34 b and the reversible pump/motor 174 due to a controlled amount of slippage in the clutch 178. The connection between the ECU 150 b and the clutch 178 (indicated by letter “A”) may be wired or wireless (for an electric or electromagnetic clutch configuration), or, the connection between the ECU 150 b and the intermediate controller for the pneumatically or hydraulically-actuated clutch 178 may be wired or wireless.

With continued reference to FIG. 3, the reversible pump/motor 174 is also selectively drivably coupled to the output shaft 50 b of the transmission 22 b at a location rearward of the transmission 22 b (i.e., relative to the front and rear of the vehicle 14 b). The reversible pump/motor 174 is selectively drivably coupled to the transmission output shaft 50 b via an offset gearbox 154 b operable to transfer torque between the transmission output shaft 50 b and the reversible pump/motor 174. Although the illustrated offset gearbox 154 b is configured having a 1:1 input/output ratio, the gearbox 154 b may be configured having a lower or higher input/output ratio. Another output shaft 158 b interconnects the offset gearbox 154 b and the rear differential 54 b. Alternatively, the output shaft 158 b may be omitted, and the gearbox 154 b may be directly coupled to the rear differential 54 b.

A second clutch 182 is positioned between the reversible pump/motor 174 and the output shaft 50 b of the transmission 22 b to allow the reversible pump/motor 174 to be selectively drivably coupled to the transmission output shaft 50 b. In a manner similar to that described above with respect to the first clutch 178, the ECU 150 b is operable to selectively actuate the second clutch 182 between a disengaged configuration, in which no torque transfer occurs between the transmission output shaft 50 b and the reversible pump/motor 174, and an engaged configuration, in which torque transfer occurs between the transmission output shaft 50 b and the reversible pump/motor 174. The clutch 182 may be configured as an electric clutch or an electromagnetic clutch operable to interface directly with the ECU 150 b, or the clutch 178 may be pneumatically or hydraulically actuated by the ECU 150 b through an intermediate controller (not shown). The ECU 150 b may control the degree of engagement of the clutch 182, such that a variable amount of torque may be transferred between the transmission output shaft 50 b and the reversible pump/motor 174 due to a controlled amount of slippage in the clutch 182. The connection between the ECU 150 b and the clutch 182 (indicated by letter “B”) may be wired or wireless (for an electric or electromagnetic clutch configuration), or, the connection between the ECU 150 b and the intermediate controller for the pneumatically or hydraulically-actuated clutch 182 may be wired or wireless.

With continued reference to FIG. 3, the reversible pump/motor 174 is in fluid communication with the reservoir 66 b to receive low-pressure working fluid via a fluid passageway 106 b. Further, the reversible pump/motor 174 is in fluid communication with the accumulator 70 b via a fluid passageway 98 b to deliver pressurized working fluid to the accumulator 70 b when operating as a pump, and to receive pressurized working fluid from the accumulator 70 b when operating as a motor. The reversible pump/motor 174 is also in fluid communication with the reservoir 66 b to return low-pressure working fluid to the reservoir 66 b via a fluid passageway 114 b.

The energy storage system 10 b also includes an isolation valve 186 positioned in the fluid passageway 98 b to selectively block the flow of working fluid through the fluid passageway 98 b. Each of the isolation valves 94 b, 186 may be configured as a poppet valve, ball valve, spool valve, gate valve, cartridge valve, needle valve, block valve, etc. Further, each of the isolation valves 94 b, 186 is solenoid-actuated to open and spring-biased to close. The ECU 150 b controls the actuation of the valves 94 b, 186 to open the valves 94 b, 186 and to allow the valves 94 b, 186 to close. The connection between the ECU 150 b and the valves 186, 94 b (indicated by letters “D” and “E,” respectively) may be wired or wireless.

By allowing the torque input to the reversible pump/motor 174 to originate from either the engine output shaft 34 b or the transmission output shaft 50 b, the energy storage system 10 b is operable in several different modes. In a first mode, for example, when it is desired to decelerate or reduce the speed of the vehicle 14 b, the second clutch 186 is engaged to allow the vehicle's axle or driveline (i.e., the rear wheels 58 b, rear differential 54 b, and the transmission output shafts 50 b, 158 b) to drive the reversible pump/motor 174 as a pump to recover the kinetic energy of the vehicle 14 b. Upon sensing the braking or equivalent energy-absorption condition, the ECU 150 b engages the second clutch 182 and actuates the isolation valves 94 b, 186 to open the valves 94 b, 186. Then, the reversible pump/motor 174 draws low-pressure working fluid from the reservoir 66 b through the fluid passageway 106 b and pressurizes the working fluid. The resultant pressurized working fluid is discharged from the reversible pump/motor 174, flows through the isolation valve 186, through the fluid passageway 98 b in the direction of arrow A, through the isolation valve 94 b, and into the working fluid chamber 86 b of the accumulator 70 b. The isolation valve 118 b in the fluid passageway 110 b remains closed to prevent the pressurized working fluid from returning to the reservoir 66 b. As the pressurized working fluid flows into the accumulator 70 b, the piston 90 b is displaced upwardly, thereby compressing the gas in the accumulator 70 b. The work performed by the piston 90 b to compress the gas is stored for later use to power the axle or driveline of the vehicle 14 b. Alternatively, the stored energy in the accumulator 70 b may be used to provide power to an auxiliary hydraulic system of the vehicle 14 b (e.g., a tailgate lift or hoist, a winch, a hydraulic cylinder, etc.). As a further alternative, the pressurized working fluid provided by the reversible pump/motor 174 may be immediately used, rather than being stored in the accumulator 70 b, to provide power to the vehicle's auxiliary hydraulic system.

Of course, this mode of operation of the system 10 b is only available when the vehicle 14 b is moving because an input torque to the reversible pump/motor 174 is required to operate the pump/motor 174 as a pump. However, because the reversible pump/motor 174 may also receive a torque input from the engine output shaft 34 b forward of the transmission 22 b, the reversible pump/motor 174 may be provided with a torque input from the engine 18 b when the vehicle 14 b is either stationary or moving. As such, in another mode of operation of the system 10 b, the reversible pump/motor 174 is operable as a pump to recover the rotational kinetic energy of the engine output shaft 34 b when the ignition of the engine 18 b is turned off (e.g., when the vehicle 14 b is decelerating or stationary to reduce extended periods of engine idling). In yet another mode of operation of the system 10 b, the reversible pump/motor 174 is operable as a pump using a torque input from the engine 18 b to provide pressurized working fluid, either directly or via the accumulator 70 b, to the auxiliary hydraulic system of the vehicle 14 b to power the auxiliary hydraulic system regardless of whether the vehicle 14 b is stationary or moving. In a further mode of operation of the system 10 b, the reversible pump/motor 174 is operable as a pump using a torque input from the engine 18 b to provide pressurized working fluid to the accumulator 70 b to pre-charge the accumulator 70 b prior to movement of the vehicle 14 b.

To operate the reversible pump/motor 174 as a pump under any of the above-described modes of operation of the system 10 b, the ECU 150 b engages the first clutch 178 and actuates the isolation valves 94 b, 186 to open the valves 94 b, 186. Then, the reversible pump/motor 174 draws low-pressure working fluid from the reservoir 66 b through the fluid passageway 106 b and pressurizes the working fluid. The resultant pressurized working fluid is discharged from the reversible pump/motor 174, flows through the isolation valve 186, through the fluid passageway 98 b in the direction of arrow A, through the isolation valve 94 b, and into the working fluid chamber 86 b of the accumulator 70 b. The isolation valve 118 b in the fluid passageway 110 b remains closed to prevent the pressurized working fluid from returning to the reservoir 66 b.

Depending upon the mode of operation of the system 10 b and the particular operating conditions of the vehicle 14 b, the ECU 150 b may control which of the first and second clutches 178, 182 is engaged to drive the reversible pump/motor 174 as a pump. Table 2 below illustrates the maximum flow rates that the reversible pump/motor 174 is capable of creating, with respect to the rotational speed of the engine 18 b and the particular gear ratio of the transmission 22 b. The values used for the transmission gear ratios include: 6.34:1 first gear; 3.44:1 second gear; 1.71:1 third gear; 1:1 fourth gear; and 0.78:1 fifth gear.

TABLE 2 Engine- Driveline-driven Driveline-driven Driveline-driven Driveline-driven Driveline-driven driven pump/motor pump/motor pump/motor pump/motor pump/motor Engine pump/motor flow rate flow rate flow rate flow rate flow rate Speed flow rate (liters/min; 1st (liters/min; 2nd (liters/min; 3rd (liters/min; 4th (liters/min; 5th (rpm) (liters/min) gear) gear) gear) gear) gear) 0 0 No fluid output when vehicle is idling and stationary 100 13 200 25 300 38 400 50 500 63 600 75 700 88 14 25 51 88 112 800 100 16 29 58 100 128 900 113 18 33 66 113 144 1000 125 20 36 73 125 160 1100 138 22 40 80 138 176 1200 150 24 44 88 150 192 1300 163 26 47 95 163 208 1400 175 28 51 102 175 224 1500 188 30 55 110 188 240 1600 200 32 58 117 200 256 1700 213 34 62 124 213 272 1800 225 35 65 132 225 1900 238 37 69 139 238 2000 250 39 73 146 250 2100 263 41 76 154 263 2200 275 43 80 161 275 2300 These values 45 84 168 These values 2400 exceed the 47 87 175 exceed the 2500 maximum 49 91 183 maximum 2600 permissible 51 94 190 permissible 2700 operating 53 98 197 operating 2800 speed of the 55 102 205 speed of the 2900 Rexroth 57 105 212 Rexroth A4VSO 3000 A4VSO 59 109 219 125 cc/rev 3100 125 cc/rev 61 113 227 pump/motor 3200 pump/motor 63 116 234 3300 65 120 241 3400 67 124 249 3500 69 127 256 3600 71 131 263 3700 73 134 270 3800 75 138 3900 77 142 4000 79 145 4100 81 149 4200 83 153 4300 85 156 4400 87 160 4500 89 164 4600 91 167 4700 93 171 4800 95 174 4900 97 178 5000 99 182

As can be seen in Table 2, the maximum permissible operating speed of the reversible pump/motor 174 serves as a limitation when the reversible pump/motor 174 can operate as a pump within the operational range of the engine 18 b (i.e., 0-5000 rpm) and the vehicle 14 b (i.e., first through fifth gears). Table 2 is illustrated graphically in FIG. 6.

With reference to FIG. 6, should the system 10 b require a flow rate of pressurized working fluid at any time when the engine 18 b is operating below about 700 rpm (i.e., while the engine 18 b is idling and the vehicle 14 b is stationary), the first clutch 178 must be engaged to drive the reversible pump/motor 174 because no torque input can be provided to the reversible pump/motor 174 through the second clutch 182 when the vehicle 14 b is stationary. Likewise, should the system 10 b require a flow rate of pressurized working fluid at any time when the engine 18 b is operating above about 2200 rpm, the second clutch 182 must be engaged to drive the reversible pump/motor 174. However, the reversible pump/motor 174 is only operable during operation of the vehicle 14 b in first, second, and third gears of the transmission 22 b above about 2200 rpm of the engine 18 b. By sensing engine speed and the transmission gear ratio, the ECU 150 b may control which of the first and second clutches 178, 182 to engage to drive the reversible pump/motor 174 as a pump to provide pressurized working fluid during any of the operational modes described above. For example, the auxiliary hydraulic system of the vehicle 14 b might require a flow rate of pressurized working fluid of about 100 liters/min when the engine 18 b is operating between about 1000-1500 rpm and the transmission 22 b is in third gear. To accommodate this requirement, toward the lower end of this engine speed range, the ECU 150 b may partially engage the first clutch 178 to provide the reversible pump/motor 174 with a torque input from the engine output shaft 34 b that would yield the 100 liters/min desired flow rate from the reversible pump/motor 174. Near the higher end of this engine speed range, the ECU 150 b may disengage the first clutch 178 and fully or partially engage the second clutch 182 to provide the reversible pump/motor 174 with a torque input from the transmission output shaft 50 b that would yield the 100 liters/min desired flow rate from the reversible pump/motor 174. Such a transition may be rapidly performed by the ECU 150 b such that the pressurized working fluid output by the reversible pump/motor 174 is substantially uninterrupted. By incorporating this capability into the system 10 b, the functionality and efficiency of the system 10 b is increased over the operating range of the engine 18 b (i.e., 0-5000 rpm) and the vehicle 14 b (i.e., first through fifth gears).

When the vehicle 14 b undergoes acceleration or another operation where propulsion assistance is needed, the reversible pump/motor 174 functions as a motor. The compressed gas acts on the piston 90 b in the accumulator 70 b, thereby maintaining the working fluid at a high pressure. Upon sensing the acceleration condition (e.g., using input from a throttle position sensor), the ECU 150 b disengages the first clutch 178, engages the second clutch 182, and actuates the isolation valves 94 b, 186 to open the valves 94 b, 186 and permit the flow of pressurized working fluid in the direction of arrow B. High-pressure working fluid flows from the accumulator 70 b, through the fluid passageway 98 b, and into the reversible pump/motor 174 to drive the reversible pump/motor 174. The reversible pump/motor 174 provides an additional torque input to the output shaft 50 b of the transmission 22 b, thereby assisting the vehicle's acceleration or other energy-expending operation. The isolation valve 118 b in the fluid passageway 110 b would remain closed to prevent the pressurized working fluid from directly returning to the reservoir 66 b. Low-pressure working fluid then exits the reversible pump/motor 174, flows through the fluid passageway 114 b in the direction of arrow C, through the heat exchanger 130 b and the filter 134 b positioned in the fluid passageway 114 b, and is subsequently returned to the reservoir 66 b.

In yet another mode of operation of the system 10 b, the reversible pump/motor 174 may be operable as a motor to start the engine 18 b using energy stored in the accumulator 70 b. This mode of operation may be employed to turn off the engine 18 b when the vehicle 14 b is stationary to reduce extended periods of engine idling. To implement this mode of operation, the ECU 150 b engages the first clutch 178 to allow the reversible pump/motor 174 to provide a torque input to the engine output shaft 34 b to start the engine 18 b. Pressurized working fluid is delivered to the reversible pump/motor 174 in this mode of operation in the same manner as that described above for providing propulsion assistance to the vehicle 14 b. In another mode of operation of the system 10 b, the reversible pump/motor 174 may be operable as a pump by engaging the first clutch 178 to circulate working fluid through the heat exchanger 130 b and filter 134 b to cool the working fluid and remove debris from the working fluid, respectively, when the vehicle 14 b is stationary and/or prior to movement of the vehicle 14 b. Further, in yet another mode of operation of the system 10 b, the reversible pump/motor 174 may be operable as a pump by engaging the first clutch 178 to circulate working fluid through the system 10 b to pre-heat the working fluid prior to movement or operation of the vehicle 14 b. In these modes of operation in which the reversible pump/motor 174 is operating as a pump, the ECU 150 b may open the valve 118 b to allow the circulating working fluid to flow through the passageway 110 b prior to merging with the fluid passageway 114 b including the heat exchanger 130 b and filter 134 b.

FIG. 4 illustrates a schematic of a fourth construction of an energy storage system 10 c for a hybrid vehicle 14 c, with like components having like reference numerals with the addition of letter “c.” Particularly, the energy storage system 10 c differs from the energy storage system 10 b of FIG. 3 in that the first clutch 178 c is drivably coupled to the power take-off or “live” PTO interface of the engine 18 c. Depending upon the particular configuration of the vehicle incorporating the energy storage system 10 b or 10 c, the energy storage system 10 c may be more desirable than the system 10 b (e.g. the vehicle 14 c may not utilize a front accessory drive system such as the accessory drive system 138 b shown in FIG. 3). The operation of the energy storage system 10 c is substantially similar to that described above for the energy storage system 10 b of FIG. 3.

Various features of the invention are set forth in the following claims. 

What is claimed is:
 1. A method of operating a hybrid vehicle including an internal combustion engine having an output shaft and a transmission operably coupled to the output shaft, the method comprising: providing an accumulator containing working fluid and gas; providing a reversible pump/motor; selectively drivably coupling the output shaft of the engine and the reversible pump/motor with a first clutch; selectively drivably coupling an output shaft of the transmission and the reversible pump/motor with a second clutch; discharging pressurized working fluid from the accumulator to the reversible pump/motor when operating as a motor; receiving pressurized working fluid discharged by the reversible pump/motor at the accumulator when operating as a pump; and controlling which of the first and second clutches to engage based upon the rotational speeds of the output shafts of the engine and the transmission, respectively.
 2. The method of claim 1, wherein selectively drivably coupling the transmission output shaft and the reversible pump/motor includes engaging the second clutch to operate the reversible pump/motor as a motor when the vehicle is at least one of stationary and moving.
 3. The method of claim 1, wherein selectively drivably coupling the transmission output shaft and the reversible pump/motor includes engaging the second clutch to operate the reversible pump/motor as a pump only when the vehicle is moving.
 4. The method of claim 3, wherein the second clutch is engaged when the engine is operating above about 2200 rpm.
 5. The method of claim 4, wherein the second clutch is engaged only when the transmission is in first, second, or third gear and the engine is operating above about 2200 rpm.
 6. The method of claim 1, wherein selectively drivably coupling the engine output shaft and the reversible pump/motor includes engaging the first clutch to operate the reversible pump/motor as a pump when the vehicle is idling and stationary. 